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Vertiv NetSure 7100 Series, Installation Manual

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Vertiv NetSure 7100 Series Installation Manual Download Page 10

 

 

Vertiv

 

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NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000)

 

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Rev. BB 

10 

Handling Equipment Containing Static Sensitive Components 

 

ALERT!  

Installation or removal of equipment containing static sensitive components requires careful 

handling.  Before handling any equipment containing static sensitive components, read and follow the 
instructions contained on the Static Warning Page. 

Maintenance and Replacement Procedures 

 

CAUTION!  

When performing any step in procedures that requires removal or installation of hardware, 

use caution to ensure no hardware is dropped and left inside the unit; otherwise service interruption or 
equipment damage may occur. 

 

NOTE!  

When performing any step in procedures that requires removal of existing hardware, retain all 

hardware for use in subsequent steps, unless otherwise directed. 

Summary of Contents for NetSure 7100 Series

Page 1: ...NetSure 7100 SERIES 48V DC Power System Installation Manual IM582127000 Revision BB Specification Number 582127000 Model Number 7100 ...

Page 2: ...plicable for the correct methods tools and materials to be used in performing procedures not specifically described in this document This document may contain confidential and or proprietary information of Vertiv Group Corporation and its receipt or possession does not convey any right to reproduce disclose its contents or to manufacture or sell anything that it may describe Reproduction disclosur...

Page 3: ... AC Input Conduit Options 17 Reversing the Enclosure Front Door 18 Placing and Securing the Relay Rack s to the Floor if applicable 20 Placing the Enclosures Bolting Enclosures Together and Securing the Enclosure s to the Floor if applicable 24 Mounting the Distribution Cabinet with Module Mounting Assembly s 30 Installing a 582127000 List 93 Battery Tray Relay Rack Installation Only 34 Installing...

Page 4: ...nput and Equipment Grounding Connections if equipped 114 External Alarm Reference Monitoring and Control Connections 123 Circuit Card Locations 123 System Interface Circuit Card 125 IB2 Controller Interface Board Connections if required Main Bay Only 127 Optional EIB Controller Extended Interface Board Connections if required Main Bay Only 132 Optional SM DU and Shunt Interface Board 138 Connectin...

Page 5: ...ery Connections to Optional Battery Busbar Extension Kit P N 554541 for system mounted in an enclosure 185 Battery Connections to Optional Battery Landing Busbar Kit P N 553584 for system mounted in a relay rack 186 Battery Connections to Optional Battery Landing Busbar Kit P N 555478 for system mounted in a relay rack 187 Installing and Connecting Batteries in List 93 Battery Tray if furnished fo...

Page 6: ... if not avoided ANSI OSHA This admonition is not used for situations that pose a risk only to equipment data or service even if such use appears to be permitted in some of the applicable standards OSHA ALERT Alerts the reader to an action that must be avoided in order to protect equipment software data or service ISO ALERT Alerts the reader to an action that must be performed in order to prevent e...

Page 7: ...ouble insulated tools appropriately rated for the work to be performed f For 400V DC input systems do not work on an energized system without full arc flash and PPE protection Voltages AC Input Voltages DANGER This system may operate from AC input voltage capable of producing fatal electrical shock AC input power must be completely disconnected from the branch circuits wiring used to provide power...

Page 8: ...rocedures involving handling installing and servicing batteries Observe all battery safety precautions in this manual and in the battery instruction manual These precautions should be followed implicitly at all times WARNING A battery can present a risk of electrical shock and high short circuit current Servicing of batteries should be performed or supervised only by properly trained and qualified...

Page 9: ...sed If battery acid enters your eye immediately flush your eye with running cold water for at least 15 minutes Get medical attention immediately If battery acid contacts skin or clothing wash immediately with soap and water ALERT Performing maintenance and or troubleshooting procedures may interrupt power to the loads if battery reserve is not sufficient Personal Protective Equipment PPE DANGER AR...

Page 10: ...ve components read and follow the instructions contained on the Static Warning Page Maintenance and Replacement Procedures CAUTION When performing any step in procedures that requires removal or installation of hardware use caution to ensure no hardware is dropped and left inside the unit otherwise service interruption or equipment damage may occur NOTE When performing any step in procedures that ...

Page 11: ...s necessary Read and follow wrist strap manufacturer s instructions outlining use of a specific wrist strap 3 Do not touch traces or components on equipment containing static sensitive components Handle equipment containing static sensitive components only by the edges that do not have connector pads 4 After removing equipment containing static sensitive components place the equipment only on cond...

Page 12: ...Vertiv NetSure 7100 Series 48V DC Power System Installation Manual IM582127000 Rev BB 12 This page is intentionally blank ...

Page 13: ... UM1M820DNA400 DC Input Voltage Systems NetSure NCU Controller User Manual NCU Controller User Instructions UM1M830BNA AC Input Voltage Systems USB Drive with All Customer Documentation Power System Quick Start Guide QS582127000 Power System Installation Instructions IM582127000 Power System Installation Instructions IM582127000100 instructions for List 100 101 102 and 103 Power System User Instru...

Page 14: ...d for you NOTE The system is not powered up until the end of this checklist NOTE Some of these procedures may have been performed at the factory for you Installing the System Relay Rack Secured to Floor if applicable Enclosures Placed Bolted Together and Secured to Floor if applicable System Components Mounted in Relay Rack if required Optional Lug Adapter Busbar Kits Installed Circuit Breakers In...

Page 15: ...tput Cables if furnished Connections to 24VDC Distribution Made as required Load Connections Made Battery Connections Made a Batteries Installed and Connected in an optional Battery Tray if furnished b Optional Battery Tray Front Battery Covers Installed if furnished c Optional Battery Tray Circuit Breaker Guards Installed if furnished Installing the Modules and Initially Starting the System Recti...

Page 16: ...ed in securing the relay rack to the floor Rectifier converter and mounting assembly ventilating openings must not be blocked and temperature of air entering rectifiers and converters must not exceed rated operating ambient temperature range found in SAG582127000 Clearance requirements are a Recommended minimum aisle space clearance for the front of each bay is 2 6 b Recommended minimum aisle spac...

Page 17: ...two corners of the panels Orient the panels as shown in Figure 1 Removing the Enclosure Side Panels Procedure 1 Loosen the fasteners on the side panel including panel frame grounding wire hardware then remove the panel Refer to Figure 1 AC Input Conduit Options Two types of conduit plates are available Select and install the conduit plate appropriate for your application Refer to Figure 2 Figure 1...

Page 18: ...s from the enclosure 4 Remove the front door 5 Reverse the front door 6 Re bolt the front door hinges to the other side of the enclosure 7 Re attach the ground strap to the front door using the saved hardware 8 Carefully remove the clips from inside the door securing the door badging emblems 9 Remove the door badging emblems and relocate them to the opposite corners at the top of the door Secure w...

Page 19: ...Vertiv NetSure 7100 Series 48V DC Power System Installation Manual IM582127000 Rev BB 19 Figure 3 Reversing the Enclosure Front Door Door Badging Emblems Hinged Door Door Inside View Hinged Door ...

Page 20: ...bays For busbar connected systems List 1 with List 2 List 3 locate relay racks in a line adjacent to each other with no space between them Place the List 1 Main Bay at the right or left side end then the List 2 Supplemental Bay then the List 3 Supplemental Bay if furnished etc Secure the relay rack to the floor per site requirements Refer to General Requirements on page 16 Ventilation Requirements...

Page 21: ...Vertiv NetSure 7100 Series 48V DC Power System Installation Manual IM582127000 Rev BB 21 Figure 4 Relay Rack Floor Mounting Dimensions cont d on next page ...

Page 22: ...y Rack Floor Mounting Dimensions cont d from previous page cont d on next page 22 500 24 50 Ref 0 000 1 000 3 500 5 030 11 000 12 530 15 030 15 62 0 437 12 Places Part No 562351 19 685 25 80 15 000 1 50 2 83 18 00 0 875 8 Places Part No 562353 12 340 22 310 3 06 1 74 Notes 1 All dimensions are in inches ...

Page 23: ...stem Installation Manual IM582127000 Rev BB 23 Figure 4 Relay Rack Floor Mounting Dimensions cont d from previous page 17 500 25 00 12 531 1 25 1 25 15 03 0 875 8 Places Part No 562355 9 871 20 125 3 75 2 44 Notes 1 All dimensions are in inches ...

Page 24: ...nstalled in an Enclosure The system consists of one to six bays Locate enclosures in a line adjacent to each other with no space between them Place the List 1 Main Bay at the right or left side end then the List 7 Supplemental Bay then the List 8 Supplemental Bay if furnished etc Refer to the following procedures Ventilation Requirements Refer to the General Requirements on page 16 Enclosure Floor...

Page 25: ...indicated in Figure 6 10 Repeat the previous step for the front enclosure joining hole at the bottom of the main enclosure 11 Repeat the above steps for the rear enclosure joining holes at the top and bottom of the main enclosure 12 Drill mounting holes in the floor for the 1st expansion enclosure Refer to Figure 5 for enclosure floor drilling dimensions 13 Place the 1st expansion enclosure in pos...

Page 26: ... enclosures as required Level the enclosures so that all enclosures are even at top Install shims between bottom of each enclosure and the floor as required to distribute floor loading and to align outside of enclosures 22 Tighten the floor mounting hardware per hardware manufacturer specifications ...

Page 27: ...lting Enclosures Together Front of Cabinet Already Installed Side of Cabinet Already Installed Torque to 150 in lbs Front of Cabinet Being Added Side of Cabinet Being Added 5 16 18 Bolt 3 5 16 Flat Washers 5 16 Ground Washer Nut 5 16 Flat Washer 5 16 Nut Mounting Hole one in each corner top and bottom ...

Page 28: ...re 7100 Series 48V DC Power System Installation Manual IM582127000 Rev BB 28 Figure 7 Installing Four 4 Thick Seismic 1 Hole Washer for Seismic Zone 4 Applications 1 4 Thick Seismic 1 Hole washer one in each corner ...

Page 29: ...chor is recommended 3 The total height of the enclosure metal surrounding each mounting hole including 1 hole washer is 0 74 18 8 mm 4 Remove the nut and washer from the anchor 5 For each anchor drop the anchor into the drilled hole Insert the anchor setting tool and hit it with a hammer to expand the anchor Placing and Securing the Enclosure to the Floor 1 Place the enclosure into position over t...

Page 30: ...he distribution cabinet with module mounting assembly s is heavy Use a hoist battery lift or other appropriate lifting device to raise and support the assembly during the installation Take appropriate precautions to avoid injury Procedure 1 Remove the distribution cabinet with module mounting assembly s from its shipping brackets Position the assembly in the equipment rack Note that part of the In...

Page 31: ...are 3 ROW CABINET 4 ROW CABINET 1 ROW CABINET 2 ROW CABINET Mounting Hardware 4 Places per Side Mounting Hardware 6 Places per Side Mounting Hardware 8 Places per Side Mounting Hardware 5 Places per Side MOUNTING HARDWARE 12 24 X 3 4 THREAD FORMING HEX HEAD SCREW NO 12 GROUND WASHER Module Mounting Assembly not shown for clarity only ...

Page 32: ...n Manual IM582127000 Rev BB 32 Figure 10 Module Mounting Assembly Spec No 588705000 and 588705500 Mounting Hardware Secure the module mounting assembly s to the relay rack MOUNTING HARDWARE 12 24 x 3 4 Thread Forming Hex Head Screw No 10 12 Ground Washer Front ...

Page 33: ...n Manual IM582127000 Rev BB 33 Figure 11 Module Mounting Assembly Spec No 588705300 and 588705400 Mounting Hardware Secure the module mounting assembly s to the relay rack MOUNTING HARDWARE 12 24 x 3 4 Thread Forming Hex Head Screw No 10 12 Ground Washer Front ...

Page 34: ... Angle Bracket Rear Angle Bracket Cabling Bracket Front Rear 1 Slide battery tray into relay rack and secure to relay rack with 12 24 x 3 4 thread forming hex head screws and 10 12 ground washers 1 place per side or 12 flat washers 3 places per side Torque to 70 in lbs 2 Secure rear angle brackets both sides to battery tray with 1 4 20 x 3 4 bolts 1 4 flat washers 1 4 lock washers and 1 4 nuts Tor...

Page 35: ...ttery Tray if furnished on page 188 Figure 13 Installing Optional Battery Disconnect Circuit Breakers onto a List 93 Battery Tray Battery Disconnect Circuit Breaker Assembly left side kit shown right side kit available 1 Remove the cover from the battery disconnect circuit breaker assembly 2 Secure the battery disconnect circuit breaker assembly to the battery tray using 6 32 x 1 2 screws and 6 32...

Page 36: ...36 Installing Optional Anderson Battery Connector Kit Procedure 1 To install an optional Anderson battery connector kit onto the List 93 Battery Tray perform the procedure in Figure 14 Figure 14 Installing Optional Anderson Battery Connector Kit onto a List 93 Battery Tray Installed View ...

Page 37: ...y if furnished on page 188 Figure 15 Installing Optional Front Battery Cover onto a List 93 Battery Tray Assembled View Kit Battery Cover Assembled to Existing Front Battery Bracket Rear View Kit Battery Cover Assembled to Existing Front Battery Bracket Front View Use kit supplied hardware Procedure 1 Install batteries 2 Install kit battery cover to existing front battery bracket 3 Install kit bat...

Page 38: ...dure 1 To install an optional circuit breaker guard onto a battery disconnect circuit breaker perform the procedure in Figure 16 Figure 16 Installing Optional Circuit Breaker Guard 1 Remove this bracket 2 Replace this hardware after removing existing bracket 3 Install Circuit Breaker Guard Bracket using existing hardware Installed View ...

Page 39: ...t 93 Battery Tray into an enclosure DANGER The enclosure must be securing anchored to the floor before the battery tray is installed Removing the Enclosure Rear and Side Panels Procedure 1 Refer to Removing the Enclosure Rear Panels and Removing the Enclosure Side Panels starting on Page 17 Installing a Battery Tray Mounting Kit P N 565004 Procedure 1 To install a Battery Tray Mounting Kit perform...

Page 40: ...Battery Tray Mounting Kit P N 565004 cont d on next page 1 Remove the twelve 12 1 4 20 x 3 4 screws locations shown Save washers and nuts for reassembly 2 Remove the two 2 1 4 20 x 1 75 screw locations shown Save washers spacers and nuts for reassembly 3 Assemble battery tray mounting kit rails in location shown ...

Page 41: ...20 x 1 screws provided with kit and saved washers and nuts locations shown Leave nuts loose at this time 6 Assemble the two 2 1 4 20 x 2 screws provided with kit and saved washers spacers and nuts locations shown Leave nuts loose 7 Ensure mounting rails are vertically leveled and the front to rear flange spacings are 6 0 8 Torque to 75 in lbs Washer Lock Washer Nut Frame Rail Spacer Washer Brace B...

Page 42: ...talling a Battery Tray Mounting Kit P N 565004 cont d from next page 9 Mount the AC guard to the cabinet 10 Remove the existing AC guard if the power system distribution is shorter than 4 row Save 8 32 x 3 8 screws 11 Install AC guards provided with kit and saved 8 32 x 3 8 screws 12 Torque to 20 in lbs ...

Page 43: ... perform the procedure in Figure 12 NOTE Do not install battery tray circuit breaker covers if provided Installing the Enclosure Rear and Side Panels Procedure 1 Fix in position the rear and side panels that were removed before installing the battery tray mounting kit Tighten the fasteners on the side panel including panel frame grounding wire hardware Refer to Figure 18 Figure 18 Installing the E...

Page 44: ...he same except as noted in the following procedure steps 1 Open the distribution cabinet s front door by turning the latch in the counterclockwise position system s in a relay rack or open the system s enclosure door 2 Install busbar extension plates as shown in Figure 19 Apply anti oxidizing compound to busbar mating surfaces before assembling Tighten bolts to the recommended torque value shown i...

Page 45: ... Cover Battery Return Side Busbar Battery Load Side Busbar GND RTN 48V SUPPLY List 24 Distribution Cabinet List 23 similar Front View 1 Apply anti oxidizing compound to busbar mating surfaces 2 Install hardware 6 places return busbar 10 places supply busbar Assembly Order 3 8 16 X 1 1 4 Bolt 3 8 Belleville Washer 3 8 Flat Washer Extension Plate System Busbar 3 Torque to 180 in lbs ...

Page 46: ...4100 Flat washer 3 8 x 1 O D 12 214825000 Belleville washer 3 8 12 227646800 Hex head bolt 3 8 16 x 1 1 4 Perform the following steps to install the battery busbar extension plates Procedure Refer to Figure 21 as the procedure is performed 1 Open the distribution cabinet front door 2 Install busbar extension plates as shown in Figure 21 Apply anti oxidizing compound to busbar mating surfaces befor...

Page 47: ...t View One Row Cabinet Shown Others Similar Battery Return Side Busbar Battery Load Side Busbar GND RTN 48V SUPPLY 1 Apply anti oxidizing compound to busbar mating surfaces 2 Install hardware 6 places per busbar Assembly Order 3 8 16 X 1 1 4 Bolt 3 8 Belleville Washer 3 8 Flat Washer Extension Plate System Busbar 3 Torque to 180 in lbs Central Office Ground ...

Page 48: ...100 Lock Washer 1 4 4 215111300 Lock Washer 3 8 6 227640400 Hex Head Bolt 1 4 20 x 3 4 not used 2 227646600 Hex Head Bolt 3 8 16 x 1 12 228557100 Nut 1 4 20 2 228567100 Nut 3 8 16 Perform the following steps to install the lug adapter busbars Procedure Refer to Figure 22 as the procedure is performed Note also the restrictions on location in Figure 22 1 Open the distribution cabinet s front door b...

Page 49: ...as shown Shield not shown Remove breakaway areas from shield as required Breakaways are only provided for positions 1 8 9 12 and 23 24 This restricts 2 and 3 pole breaker adapter kits to be located in these positions only Circuit breaker locations for reference only Busbar Adapter Kit P N 534449 Busbar Adapter Kit P N 514714 Busbar Adapter Kit P N 534449 ...

Page 50: ...wing steps to install the lug adapter busbars Procedure Refer to Figure 23 as the procedure is performed 1 Open the distribution cabinet s front door by turning the latch in the counterclockwise position system s in a relay rack or open the system s enclosure door 2 Install the lug adapter busbars as shown in Figure 23 Apply anti oxidizing compound to busbar mating surfaces before assembling Refer...

Page 51: ...20 x 3 4 Bolt 6 places Torque to 60 in lbs supplied with breaker mounting kit Busbar Adapter Kit P N 562888 Torque to 300 in lbs when using 3 8 inch hardware with standard flat and lock washer Apply anti oxidizing compound to busbar mating surfaces LOAD RETURN BUSBAR 3 8 16 Captive Nuts on 1 Centers Customer must supply or order hardware OFF ON Shorting Busbar supplied with breaker mounting kit Sh...

Page 52: ...k or open the system s enclosure door 2 Orient the fuseholder as shown in Figure 24 Insert the terminals on the rear of the fuseholder into their corresponding sockets on the distribution panel Ensure the alarm contact on the back of the fuseholder makes contact with the alarm terminal on the spring strip Push fuseholder in firmly until fully seated in the distribution panel 3 When all fuseholders...

Page 53: ... Side to the Top Fuse Carrier Fuseholder Body TPS TLS Fuse Polarizing Keyway Matches Key on Bottom of Fuse Carrier Fuseholder Assembly Exploded View Fuseholder Assembly P N 117201 includes body carrier alarm fuse and alarm fuse safety cover Insert these terminals into corresponding sockets on distribution panel GMT X Safety Fuse Cover Replacement P N 248898700 GMT 18 100A Alarm Fuse Replacement P ...

Page 54: ...on system s in a relay rack or open the system s enclosure door 2 Ensure that the circuit breaker is in the OFF position and is of the correct rating Orient the circuit breaker as shown in Figure 25 Insert the terminals on the rear of the circuit breaker into their corresponding sockets on the distribution panel Ensure the alarm contact on the back of the circuit breaker makes contact with the ala...

Page 55: ... s in a relay rack or open the system s enclosure door 2 Follow the steps in Figure 26 3 Install an appropriately sized GMT fuse in each fuse mounting position on the GMT Distribution Fuse Block as required If dummy fuses are installed first remove the dummy fuse a Verify that dummy fuses are installed in all unused fuse positions on the GMT distribution fuse block b Verify that a plastic safety c...

Page 56: ...ition GMT Distribution Fuse Block P N 550224 Press in tabs to release lug terminal busbars for positions to be occupied by GMT Fuse Block Remove two lug terminal busbars for positions to be occupied by GMT Fuse Block Plug in GMT Fuse Block and secure at two locations on the RTN bar Torque to 72 in lbs RTN Bar GMT Fuse Block Installed View 1 2 3 ...

Page 57: ...door 2 Follow the steps in Figure 27 3 Install an appropriately sized GMT fuse in each fuse mounting position on the GMT Distribution Fuse Block as required If dummy fuses are installed first remove the dummy fuse a Verify that dummy fuses are installed in all unused fuse positions on the GMT distribution fuse block b Verify that a plastic safety cover is installed on all GMT fuses on the GMT dist...

Page 58: ...e 6 Position GMT Distribution Fuse Block P N 549017 RTN Bar 1 Remove two lug terminal busbars for positions to be occupied by GMT Fuse Block Remove plastic busbar plugs first Plastic Busbar Plugs 2 Plug in GMT Fuse Block 3 Connect supplied jumper from GMT Fuse Block to Return Bar Torque to 75 in lbs Part of P N 549017 Part of P N 549017 ...

Page 59: ...r 2 Remove the TPH fuse carrier from the mounted fuseholder body by grasping its handle and firmly pulling it straight out Install the TPH fuse into the fuse carrier When done push the fuse carrier securely back into the mounted fuseholder body 3 Verify that a 1 4 ampere alarm fuse is installed in the GMT type fuseholder located adjacent to the TPH fuseholder and that a plastic safety cover is ins...

Page 60: ...rack or open the system s enclosure door 2 Remove the fuse case from the mounted fuse block by grasping its handle and pulling it straight out 3 Verify that an 18 100 ampere alarm fuse is present in the GMT type fuseholder located on the fuse block and that a plastic safety cover is installed on this fuse 4 Open the fuse case 5 Install the TPL fuse into the fuse case 6 Close the fuse case 7 Firmly...

Page 61: ... Figure 29 Installing TPL B Fuses Fuse Case Open Fuse Case View TPL Fuse Fuse Installed in Open Fuse Case rear view Fuse Installed in Closed Fuse Case rear view Fuseblock P N 516241 GMT 18 100A Alarm Fuse P N 248610301 and GMT X Safety Fuse Cover P N 248898700 Both are provided w fuseblock ...

Page 62: ...ion panel and the circuit breaker Orient the circuit breaker over its mounting location a Attach the alarm jumper connectors to the back of the circuit breaker then plug the other end of the alarm jumper into its corresponding connector See Figure 30 b Shunted Breakers Only Attach the shunt jumper connectors to the back of the circuit breaker then route the jumper through the hole in the distribut...

Page 63: ...es before mounting circuit breakers INSTALLING CIRCUIT BREAKER Alarm jumper connector Holes to route shunt jumper through if applicable ALARM WIRING BREAKERS W OUT SHUNTS ALARM WIRING BREAKERS WITH SHUNTS Standard and Electrical Trip Breaker Shunted Breaker Jumper Red Alarm Jumper Brown Alarm Jumper Brown Alarm Jumper Red Alarm Jumper Red Shunted Breaker Jumper Black INSTALLING CIRCUIT BREAKER GUA...

Page 64: ...per Red Shunted Breaker Jumper Black INSTALLING CIRCUIT BREAKER GUARD ON OFF LONGER SIDE OF GUARD 10 32 X 7 16 PH 10 32 LW CIRCUIT BREAKER GUARD LABEL CIRCUIT BREAKER GUARD TYPICAL DIST ASSY SHOWN FOR EXAMPLE 1 4 Hardened Flat Washer 1 4 Belleville Lock Washer 1 4 20 x 3 4 Bolt 4 places 2 pole brk 6 places 3 pole brk 8 places 4 pole brk Torque to 60 in lbs Apply anti oxidizing compound to busbar m...

Page 65: ...RD 10 32 X 7 16 PH 10 32 LW CIRCUIT BREAKER GUARD LABEL CIRCUIT BREAKER GUARD TYPICAL DIST ASSY SHOWN FOR EXAMPLE Apply anti oxidizing compound to busbar mating surfaces before mounting circuit breakers 1 4 Hardened Flat Washer 1 4 Belleville Lock Washer 1 4 20 x 3 4 Bolt 2 places Torque to 60 in lbs OFF ON OFF ON Alarm jumper connector 1 4 Hardened Flat Washer 1 4 Belleville Lock Washer 1 4 20 x ...

Page 66: ...ion for Clarity Controller System Interface Circuit Card OR Optional LVD Driver Circuit Card Optional LVD Inhibit Switch factory installed if option specified Optional LVD Driver Lite Circuit Card Optional Manual Battery Disconnect Circuit Card Main Bay Only IB2 Main Bay Only Interface Board located on inside side panel Optional EIB Main Bay Only Extended Interface Board located on inside side pan...

Page 67: ...ual IM582127000 Rev BB 67 Figure 31 Circuit Card Locations Supplementary Bay 4 Row Cabinet Shown Others Similar Illustration for Clarity CAN Interface Card OR Optional LVD Driver Circuit Card Optional LVD Driver Lite Circuit Card System Interface Circuit Card SM DU ...

Page 68: ...attery power allows the controller to stay running in the event rectifiers are off or battery LVD opens if installed Note that if powering the controller from battery the battery will drain if rectifiers are off or battery LVD opens if installed The controller s power consumption is 5W Procedure 1 Refer to Figure 32 and place the jumper on J8 in the Battery Pwr or No Battery Pwr position Internal ...

Page 69: ... J3 J4 J8 TB2 TB1 TP1 TP2 TP3 TP4 J10 J5 TB1 2 TB1 3 TB1 4 TB1 5 Main Bay Only TB1 4 External Battery Monitoring TB1 5 External Battery Monitoring 4 Row Cabinet Shown Others Similar Front Door Removed in Illustration for Clarity System Interface Circuit Card System Interface Circuit Card External Internal J10 1 2 3 7 8 9 J10 Main Bay Only Battery Monitoring External Internal see TB1 4 and TB1 5 fo...

Page 70: ...ional IB2 2 in Main Bay ON OFF Switch Setting on Optional EIB Interface Board Main Bay Only Dip Switch SW1 on the EIB board is used to set the communications address for this board Refer to Table 2 for SW1 settings Refer to Figure 34 for SW1 location Perform the following procedure to verify the factory settings This procedure can also be used to make adjustments on a replacement circuit card Proc...

Page 71: ...Location and Settings installed in Main Bay only J12 SW1 J2 J11 J9 J8 J7 J6 J5 J4 J3 IB2 Interface Board Top View Switch SW1 is located in this corner of the IB2 Board on off 1 2 Setting DIP Switch SW1 1 2 OFF OFF Optional IB2 2 in Main Bay ON OFF IB2 1 in Main Bay ON OFF 1 2 SW1 Refer to table for Optional IB2 switch setting ...

Page 72: ...ttings installed in Main Bay only SW1 In this system switch settings must be in positions shown Optional EIB Interface Board Top View Switch SW1 is located in this corner of the EIB Board SW1 on off 1 2 ON OFF 1 2 SW1 Setting DIP Switch SW1 1 2 OFF OFF Optional EIB 2 in Main Bay ON OFF EIB 1 in Main Bay Refer to table for Optional EIB switch setting ...

Page 73: ...the following procedure to verify the factory settings This procedure can also be used to make adjustments on a replacement circuit card Procedure 1 Ensure S1 S2 and S3 are set per Table 3 Refer to Figure 35 for location Figure 35 SM DU Switch Location Supplemental Bay Addressing 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 SM DU Circuit Card S1 S2 S3 JP1 JP2 JP3 J5 J4 J4A J3 J1 J2 Power CAN RS...

Page 74: ...Address 3 Setting for SM DU in 3rd Supp Bay ON OFF OFF Address 4 Setting for SM DU in 4th Supp Bay ON OFF ON Address 5 Setting for SM DU in 5th Supp Bay ON ON OFF Address 6 ON ON ON Address 7 NA OFF OFF NA Shunt Voltage 75mV OFF ON Shunt Voltage 25mV Note 1 ON OFF Shunt Voltage 50mV ON ON Shunt Voltage 60mV NA OFF OFF OFF Shunt Current 500A Note 1 OFF OFF ON Shunt Current 100A OFF ON OFF Shunt Cur...

Page 75: ...F ON Shunt 1 is Used for Battery ON OFF Shunt 1 is Used for Load Note 1 ON ON Set via Software NA OFF OFF NA Shunt 2 is Disabled OFF ON Shunt 2 is Used for Battery Note 1 ON OFF Shunt 2 is Used for Load ON ON Set via Software NA OFF OFF NA Shunt 3 is Disabled Note 1 OFF ON Shunt 3 is Used for Battery ON OFF Shunt 3 is Used for Load ON ON Set via Software NA OFF OFF Shunt 4 is Disabled Note 1 OFF O...

Page 76: ...te 1 NA Off NA Bi Stable Contactor Note 1 On Mono Stable Contactor NA Off NA LVD reconnection is disabled upon communication failure On LVD reconnection is enabled upon communication failure Note 1 NA On LVD2 is a Dry Contact Off LVD2 Note 1 DIP Switch S3 Shunt 5 Setting Reserved Calibration Mode Description of Status 5 6 7 8 Off Off NA Shunt 5 is Disabled Note 1 Off On Shunt 5 is Used for Battery...

Page 77: ...rd Procedure Ensure SW1 and SW2 are set per Table 4 Refer to Figure 36 for location Figure 36 Optional SM DU Switch Location and Settings SM DU and Shunt Interface Board SM DU Switches SW1 and SW2 are located in this corner of the SM DU SW1 SW2 on 5 6 7 8 1 2 3 4 off on 5 6 7 8 1 2 3 4 off SW1 and SW2 In this system switch settings must be in the positions shown except adressing switches which mus...

Page 78: ...t 100A OFF ON OFF Shunt Current 200A OFF ON ON Shunt Current 300A ON OFF OFF Shunt Current 400A ON OFF ON Shunt Current 1000A ON ON OFF Shunt Current 1500A ON ON ON Shunt Current 2000A DIP Switch SW2 Reserved Communications Address Baud Rate Description of Status 1 2 3 4 5 6 7 8 NA OFF OFF OFF NA Address 1 Setting for SM DU in Main Bay OFF OFF ON Address 2 Setting for SM DU in 1st Supp Bay OFF ON ...

Page 79: ...stem Application Guide SAG582127000 Lugs should be crimped per lug manufacturer s specifications Refer to Table 5 for supplemental lug crimping information when using the special application crimp lug strap combination Table 5 Supplemental Lug Crimping Information when using the Special Application Crimp Lug Strap Combination Crimp Lug Part No Crimp Tool Required1 T B Model TBM12 or TBM15 Hydrauli...

Page 80: ...ole lug that has 1 4 bolt clearance holes on 5 8 centers When using 1 4 inch hardware recommended torque is 84 in lbs when a standard flat washer and lock washer are used Refer to Figure 37 for locations NOTE REMOVE TAPE IF PRESENT FROM HOLE LOCATIONS BEFORE INSTALLING LUG NOTE The DC return connection to this system can remain isolated from system frame and chassis DC I NOTE This system is suitab...

Page 81: ...nclosure Frame Grounding Connection Points Frame Ground Connection Point 1 4 clearance holes on 5 8 centers Frame Ground Connection Point 1 4 clearance holes on 5 8 centers Frame Ground Connection Point 1 4 20 Clinch Nuts on 5 8 centers Top View Typical Relay Rack Top View Typical Relay Rack Top View Typical Cabinet ...

Page 82: ...0 List 01 03 21 588705400 List 01 02 03 04 588705500 List 01 02 03 04 05 Wiring Considerations For wire size branch circuit protection crimp lug and general wiring recommendations refer to System Application Guide SAG582127000 AC Input Termination Assemblies The available AC input options for this system are The system can be equipped with an AC input termination assembly which provides a separate...

Page 83: ... one for each rectifier module position 588705000 List 22 588705500 List 02 The system can be equipped with module mounting assemblies that contain AC input cable assemblies or AC input line cords which provide a separate single phase AC input connection for every two 2 rectifier positions 588705300 List 03 The system can be equipped with module mounting assemblies that contain AC input cable asse...

Page 84: ...nation Assembly Plug buttons are provided and must be installed in the openings not being used 3 Route wiring into the AC Input Termination Assembly through the previously installed conduit fittings Making AC Input Connections 1 Make AC input connections as shown in Figure 38 Figure 39 Figure 40 or Figure 41 Connect each wire by inserting the stripped end into the wire opening and then tightening ...

Page 85: ...AC 50 Hz 60Hz SINGLE PHASE SHELF 3 SHELF 2 AC 2 AC 1 PCU 1 AC 2 AC 1 PCU 2 AC 2 AC 1 PCU 3 AC 2 AC 1 PCU 1 AC 2 AC 1 PCU 2 AC 2 AC 1 PCU 3 RECTIFIER PCU AC INPUT FEEDS 1 FEED PER 1 RECTIFIER PCU 208 VAC 240 VAC 277 VAC 50 Hz 60Hz SINGLE PHASE SHELF 5 SHELF 4 AC 2 AC 1 PCU 4 AC 2 AC 1 PCU 5 AC 2 AC 1 PCU 6 RECTIFIER PCU AC INPUT FEEDS 1 FEED PER 1 RECTIFIER PCU 208 VAC 240 VAC 277 VAC 50 Hz 60Hz SI...

Page 86: ...U 208 VAC 240 VAC 277 VAC 50 Hz 60Hz SINGLE PHASE SHELVES 1 AND 2 AC Wireway Cover AC Wireway Cover AC Input Connector Cover FRAME GROUND CONNECTION Four 10 32 X 3 4 Studs and Hardware Recommended torque 23 in lbs FRAME GROUND CONNECTION Four 10 32 X 3 4 Studs and Hardware Recommended torque 23 in lbs Line to Line Connect Line 1 to Terminal L1 Connect Line 2 to Terminal L2 N Line to Neutral Connec...

Page 87: ...50 Hz 60Hz SINGLE PHASE SHELVES 1 AND 2 AC Wireway Cover AC Wireway Cover AC Input Connector Cover FRAME GROUND CONNECTION Four 10 32 X 3 4 Studs and Hardware Recommended torque 23 in lbs FRAME GROUND CONNECTION Four 10 32 X 3 4 Studs and Hardware Recommended torque 23 in lbs Line to Line Connect Line 1 to Terminal L1 Connect Line 2 to Terminal L2 N Line to Neutral Connect Line to Terminal L1 Conn...

Page 88: ...FIER PCU AC INPUT FEEDS 1 FEED PER 2 RECTIFIERS PCU 208 VAC 240 VAC 277 VAC 50 Hz 60Hz SINGLE PHASE SHELVES 1 AND 2 AC Wireway Cover AC Wireway Cover AC Input Connector Cover FRAME GROUND CONNECTION Four 10 32 X 3 4 Studs and Hardware Recommended torque 23 in lbs FRAME GROUND CONNECTION Four 10 32 X 3 4 Studs and Hardware Recommended torque 23 in lbs Line to Line Connect Line 1 to Terminal L1 Conn...

Page 89: ...SHELF GND GND GND GND PCU 1 PCU 2 PCU 3 RECTIFIER PCU AC INPUT FEEDS 1 FEED PER 2 RECTIFIERS PCU 208 VAC 240 VAC 277 VAC 50 Hz 60Hz SINGLE PHASE SHELVES 1 AND 2 PCU 4 PCU 5 PCU 6 RECTIFIER PCU AC INPUT FEEDS 1 FEED PER 2 RECTIFIERS PCU 208 VAC 240 VAC 277 VAC 50 Hz 60Hz SINGLE PHASE SHELVES 1 AND 2 AC Wireway Cover AC Wireway Cover AC Input Connector Cover FRAME GROUND CONNECTION Four 10 32 X 3 4 ...

Page 90: ...E WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF GND GND GND GND RECTIFIER PCU AC INPUT FEEDS 1 FEED PER 2 RECTIFIERS PCU 208 VAC 240 VAC 277 VAC 50 Hz 60Hz SINGLE PHASE SHELF 1 RECTIFIER PCU AC INPUT FEEDS 1 FEED PER 2 RECTIFIERS PCU 208 VAC 240 VAC 277 VAC 50 Hz 60Hz SINGLE PHASE SHELF 1 AC Wireway Cover AC Wireway Cover AC Input Connector Cover FRAME GROUND CONNECTION Four 1...

Page 91: ...R PCU AC INPUT FEEDS 1 FEED PER 3 RECTIFIERS PCU 208 VAC 240 VAC 50 Hz 60Hz THREE PHASE SHELF 1 PCUs 4 6 C B A RECTIFIER PCU AC INPUT FEEDS 1 FEED PER 3 RECTIFIERS PCU 208 VAC 240 VAC 50 Hz 60Hz THREE PHASE SHELF 2 PCUs 4 6 C B A SHELF 3 PCUs 4 6 C B A RECTIFIER PCU AC INPUT FEEDS 1 FEED PER 3 RECTIFIERS PCU 208 VAC 240 VAC 50 Hz 60Hz THREE PHASE SHELF 4 PCUs 4 6 C B A SHELF 5 PCUs 4 6 FRAME GROUN...

Page 92: ...VAC 50 Hz 60Hz THREE PHASE SHELF 1 PCUs 4 6 RECTIFIER PCU AC INPUT FEEDS 1 FEED PER 3 RECTIFIERS PCU 277 VAC 480 VAC 50 Hz 60Hz THREE PHASE SHELF 2 PCUs 4 6 SHELF 3 PCUs 4 6 RECTIFIER PCU AC INPUT FEEDS 1 FEED PER 3 RECTIFIERS PCU 277 VAC 480 VAC 50 Hz 60Hz THREE PHASE SHELF 4 PCUs 4 6 SHELF 5 PCUs 4 6 FRAME GROUND CONNECTION Four 10 32 X 3 4 Studs and Hardware Recommended torque 23 in lbs FRAME G...

Page 93: ...tons are provided and must be installed in the openings not being used 3 Inside the distribution cabinet remove the two AC input connector covers by first loosening the fasteners that secure each of them 4 Route wiring into the enclosure through the previously installed conduit fittings Making AC Input Connections 1 Make AC input connections as shown in Figure 42 Figure 43 Figure 44 or Figure 45 C...

Page 94: ...helf 2 Shelf 3 Shelf 4 Shelf 5 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Shelf 6 Note Customer wiring to top terminals of terminal blocks For fewer power shelves than shown only the connections for the installed shelves are present SHELF 1 PCU 6 L1 L2 N PCU 5 L1 L2 N PCU 4 L1 L2 N PCU 6 L1 L2 N PCU 5 L1 L2 N PCU 4 L1 L2 N PCU 6 L1 L2 N PCU 5 L1 L2 N PCU 4 L1 L2 N PCU 6 L1 L...

Page 95: ...Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Shelf 2 Shelf 3 Shelf 4 Shelf 5 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Shelf 6 Note Customer wiring to top terminals of terminal blocks For fewer power shelves than shown only the connections for the installed shelves a...

Page 96: ...ct PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Shelf 2 Shelf 3 Shelf 4 Shelf 5 Note Customer wiring to top terminals of terminal blocks For fewer power shelves than shown only the connections for the installed shelves are present...

Page 97: ... 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Shelf 2 Shelf 3 Shelf 4 Note Customer wiring to top terminals of terminal blocks For fewer power shelves than shown only the connections for the installed shelves are...

Page 98: ...Module PCU Mounting Slots Shelf 1 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Shelf 2 Shelf 3 Note Customer wiring to top terminals of terminal blocks For fewer power shelves than shown only the connections for the installed shelves are present S...

Page 99: ...S DONE AT THE REAR OF THE SHELF AC Input Connector Cover Rectifier Module PCU Mounting Slots Shelf 1 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Shelf 2 Note Customer wiring to top terminals of terminal blocks For fewer power shelves than shown only the connections for the installed shelves are present SHELVES ...

Page 100: ... Right Side NOTE WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF AC Input Connector Cover Rectifier Module PCU Mounting Slots Shelf 1 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Note Customer wiring to top terminals of terminal blocks For fewer power shelves than shown only the connections for the installed shelves are present SHELF 1 PCU 5 6 L1 L2 N PCU 3 ...

Page 101: ...Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Shelf 2 Shelf 3 Shelf 4 Shelf 5 Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Shelf 6 Note Customer wirin...

Page 102: ...CU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 Shelf 6 Note Customer wiring to top terminals of terminal blocks For fewer power shelves than shown only the connections for the installed shelves are present SHELF 2 PCUs 1 3 L3 L2 L1 N L3 L2 L1 N SHELF 1 PCUs 1 3 SHELF 4 PCUs 1 3 L3 L2 L1 N L3 L2 L1 N SHELF 3 PCUs 1 3 SHELF 6 PCUs 1 3 L3 L2 L1 N L3 L2 L1 N SHELF 5 PCUs 1 3 SHELF 1 PCUs 4 6 N L3 L2...

Page 103: ... Wire 1 Remove the two AC input access covers from the rear of the module mounting assembly by first removing the screws that secure them 2 Install conduit fittings in the side or rear openings as required Plug buttons are provided and must be installed in the openings not being used 3 Route wiring into the shelf through the previously installed conduit fittings Making AC Input Connections NOTE In...

Page 104: ...1 and 588705500 List 03 Module Mounting Assembly Module Mounting Assembly Left Side as Viewed from Rear 208 VAC 240 VAC 277 VAC Service Type Line to Line Connect Line 1 to Terminal 1 Connect Line 2 to Terminal 2 Line to Neutral Connect Line to Terminal 1 Connect Neutral to Terminal 2 Right Side as Viewed from Rear PCU 4 1 1 PCU 1 2 2 PCU 5 1 1 PCU 2 2 2 PCU 6 1 1 PCU 3 2 2 ...

Page 105: ...HARDWARE Recommended torque 23 in lbs Rectifier Module PCU Mounting Slots front view Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 1 2 1 2 AC IN Rectifier Module 4 1 2 Rectifier Module 5 Rectifier Module 6 AC IN Rectifier Module 1 Rectifier Module 2 Rectifier Module 3 1 2 1 2 1 2 RECTIFIER PCU AC INPUT FEEDS INDIVIDUAL RECTIFIER PCU FEED 208 VAC 240 VAC 277 VAC 50 Hz 60 Hz SING...

Page 106: ...in the power system Accessing Connections and Routing Wire 1 Remove the two AC Input Access Covers from the rear of the module mounting assembly by first removing the screws that secure them 2 Install conduit fittings in the side or rear openings as required Plug buttons are provided and must be installed in the openings not being used 3 Route wiring into the shelf through the previously installed...

Page 107: ...NECTION ONE 10 32 X 3 4 STUD AND HARDWARE Recommended torque 23 in lbs Rectifier Module PCU Mounting Slots front view Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 AC IN Feed 2 Rectifier Modules 4 6 AC IN Feed 1 Rectifier Modules 1 3 1 ØA 2 ØB 3 ØC 1 ØA 2 ØB 3 ØC L1 L2 L1 L2 L1 L2 L1 L2 L1 L2 L1 L2 CONNECTIONS WITHIN THE SHELF Mounting Position Rect 1 Rect 2 Rect 3 Rect 4 Rect ...

Page 108: ...CTION ONE 10 32 X 3 4 STUD AND HARDWARE Recommended torque 23 in lbs Rectifier Module PCU Mounting Slots front view Rect PCU 1 Rect PCU 2 Rect PCU 3 Rect PCU 4 Rect PCU 5 Rect PCU 6 AC IN Feed 2 Rectifier Modules 4 6 AC IN Feed 1 Rectifier Modules 1 3 RECTIFIER PCU AC INPUT FEEDS 1 FEED PER 3 RECTIFIERS PCU 277 VAC 480 VAC 50 Hz 60 Hz THREE PHASE Wire Size Capacity 8 24 AWG Recommended Torque 18 i...

Page 109: ...cord into a properly wired AC outlet or distribution box Refer to Figure 49 Figure 49 Nominal 208 VAC 240 VAC Input and Equipment Grounding Connections to Module Mounting Assembly 588705000 List 22 and 588705500 List 02 Single Phase Line Cords Rectifier Module 4 Rectifier Module 6 Rectifier Module 5 Rectifier Module 1 Rectifier Module 3 Rectifier Module 2 Rear View Rectifier Module PCU Mounting Sl...

Page 110: ...rds connected here Rectifiers are numbered left to right as viewed from the front AC Input for Rectifier Positions 5 and 6 AC Input for Rectifier Positions 1 and 2 AC Input for Rectifier Positions 3 and 4 Rear Rear M4 Frame Ground Studs Located Behind Cover Input Connections are Made using the Ordered Input Cable Assemblies Line Cords Cabinet Rear View L2 N Ground L1 Blue Green Yellow Brown White ...

Page 111: ...for Rectifier Position 1 AC Input for Rectifier Position 2 Rear AC Input for Rectifier Position 6 AC Input for Rectifier Position 4 AC Input for Rectifier Position 5 Input Connections are Made using the Ordered Input Cable Assemblies Line Cords Cabinet Rear View L2 Ground L1 Blue Green Yellow Brown White Green Black Color of Input Cable Assembly Line Cord Lead Rectifier AC Input 208 VAC 240 VAC 30...

Page 112: ...Module Mounting Assembly Rectifier AC input connections are made using the supplied AC input line cords connected here Rear Rectifiers are numbered left to right as viewed from the front AC Input for Rectifier Positions 1 2 3 Rear AC Input for Rectifier Positions 4 5 6 Input Connections are Made using the Ordered Input Line Cords White Black Red Green L1 L2 L3 Ground Color of Input Line Cord Lead ...

Page 113: ...Assembly Rectifier AC input connections are made using the supplied AC input line cords connected here Rear M4 Frame Ground Screw M4 Frame Ground Screw Rectifiers are numbered left to right as viewed from the front AC Input for Rectifier Positions 1 2 3 Rear AC Input for Rectifier Positions 4 5 6 White Black Red Orange Green N L1 L2 L3 Ground Color of Input Line Cord Lead Module Input Connector Ca...

Page 114: ...ion assembly which provides a separate DC input connection for every three 3 converter positions 582127000 List 47 Direct DC Input Connections to the Module Mounting Assemblies The system can be equipped with module mounting assemblies that contain DC input terminal blocks which provide a separate DC input connection for each converter position 588705000 List 41 The system can be equipped with mod...

Page 115: ...nto the wire opening and then tightening the screw Torque connections to value shown in the appropriate illustration NOTE Terminal blocks for a system with maximum possible converter shelves shown Your system may have less terminal blocks then shown Making Equipment Grounding Connections 1 Connect equipment grounding leads to the frame ground studs using installer provided ring lugs and factory su...

Page 116: ...nv 1 Conv 2 Conv 3 Conv 4 Conv 5 Conv 6 Shelf 2 Shelf 3 Shelf 4 Shelf 5 Conv 1 Conv 2 Conv 3 400 VDC CONVERTER DC INPUT FEEDS 1 FEED PER 1 CONVERTER SHELF 1 Conv 1 Conv 2 Conv 3 Conv 1 Conv 2 Conv 3 400 VDC CONVERTER DC INPUT FEEDS 1 FEED PER 1 CONVERTER SHELF 3 SHELF 2 Conv 1 Conv 2 Conv 3 Conv 1 Conv 2 Conv 3 400 VDC CONVERTER DC INPUT FEEDS 1 FEED PER 1 CONVERTER SHELF 5 SHELF 4 Conv 4 Conv 5 C...

Page 117: ...odule Mounting Slots Shelf 1 Conv 1 Conv 2 Conv 3 Conv 4 Conv 5 Conv 6 Conv 1 Conv 2 Conv 3 Conv 4 Conv 5 Conv 6 Conv 1 Conv 2 Conv 3 Conv 4 Conv 5 Conv 6 Conv 1 Conv 2 Conv 3 Conv 4 Conv 5 Conv 6 Shelf 2 Shelf 3 Shelf 4 Conv 1 Conv 2 Conv 3 400 VDC CONVERTER DC INPUT FEEDS 1 FEED PER 2 CONVERTERS SHELVES 1 AND 2 Conv 1 Conv 2 Conv 3 400 VDC CONVERTER DC INPUT FEEDS 1 FEED PER 2 CONVERTERS SHELVES...

Page 118: ...v 1 3 SHELF 2 Conv 1 3 Converter Module Mounting Slots Shelf 1 Conv 1 Conv 2 Conv 3 Conv 4 Conv 5 Conv 6 Conv 1 Conv 2 Conv 3 Conv 4 Conv 5 Conv 6 Conv 1 Conv 2 Conv 3 Conv 4 Conv 5 Conv 6 Conv 1 Conv 2 Conv 3 Conv 4 Conv 5 Conv 6 Conv 1 Conv 2 Conv 3 Conv 4 Conv 5 Conv 6 Shelf 2 Shelf 3 Shelf 4 Shelf 5 400 VDC CONVERTER DC INPUT FEEDS 1 FEED PER 3 CONVERTERS SHELF 5 Conv 1 3 SHELF 4 Conv 1 3 400 ...

Page 119: ... Connections and Routing Wire 1 Remove the two DC input access covers from the rear of the module mounting assembly by first removing the screws that secure them 2 Install conduit fittings in the side or rear openings as required Plug buttons are provided and must be installed in the openings not being used 3 Route wiring into the shelf through the previously installed conduit fittings Making DC I...

Page 120: ...View Converter Module Mounting Slots front view Conv 1 Conv 2 Conv 3 Conv 4 Conv 5 Conv 6 Wire Size Capacity 10 20 AWG Recommended Torque 10 in lbs FRAME GROUND CONNECTION ONE 10 32 X 3 4 STUD AND HARDWARE Recommended torque 23 in lbs FRAME GROUND CONNECTION ONE 10 32 X 3 4 STUD AND HARDWARE Recommended torque 23 in lbs 400 VDC IN Converter Module 4 Converter Module 5 Converter Module 6 Converter ...

Page 121: ...ssing Connections and Routing Wire 1 Remove the two DC Input Access Covers from the rear of the module mounting assembly by first removing the screws that secure them 2 Install conduit fittings in the side or rear openings as required Plug buttons are provided and must be installed in the openings not being used 3 Route wiring into the shelf through the previously installed conduit fittings Making...

Page 122: ...odule Mounting Slots front view Conv 1 Conv 2 Conv 3 Conv 4 Conv 5 Conv 6 CONVERTER 400 VDC INPUT FEEDS 1 FEED PER 3 CONVERTERS Holes for 3 4 Conduit Fitting Input Rear View FRAME GROUND CONNECTION ONE 10 32 X 3 4 STUD AND HARDWARE Recommended torque 23 in lbs FRAME GROUND CONNECTION ONE 10 32 X 3 4 STUD AND HARDWARE Recommended torque 23 in lbs 400 VDC IN Feed 2 Converter Modules 4 6 400 VDC IN F...

Page 123: ... in Illustration for Clarity Controller System Interface Circuit Card OR Optional LVD Driver Circuit Card Optional LVD Inhibit Switch factory installed if option specified Optional LVD Driver Lite Circuit Card Optional Manual Battery Disconnect Circuit Card Main Bay Only IB2 Main Bay Only Interface Board located on inside side panel Optional EIB Main Bay Only Extended Interface Board located on in...

Page 124: ...al IM582127000 Rev BB 124 Figure 59 Circuit Card Locations Supplementary Bay 4 Row Cabinet Shown Others Similar Illustration for Clarity CAN Interface Card OR Optional LVD Driver Circuit Card Optional LVD Driver Lite Circuit Card System Interface Circuit Card SM DU ...

Page 125: ... power system distribution cabinet Application of system voltage to pin TB1 3 activates this alarm The lead should be protected at the source with an in line fusible resistor This input is not to be used for any voltage bus such as converter output other than the system bus External Battery Monitoring circuit card installed in Main Bay only If the jumper J10 is set to External see Figure 32 connec...

Page 126: ...ity 16 26 AWG Recommended Torque 2 0 in lbs When an NCU configuration is furnished that enables NCU capability to receive status information sent from Fiamm SoNick Sodium Nickel batteries Connect leads from the Fiamm SoNick batteries to the RS 485 terminals Refer to the battery manufacturer documentation and the NCU controller manual UM1M830BNA for details J1 J2 J3 J4 Distribution Panels FA Inputs...

Page 127: ...onverters opens the LVD s and shuts down the optional 48V to 24V DC converters When the ESTOP signal is removed LVD s close if battery present and 48V to 24V DC converters restart To restart the rectifiers or 400V DC input converters turn input power to the rectifiers converters OFF wait 30 seconds or more until the LEDs on the module extinguish then turn input power to the rectifiers converters O...

Page 128: ...pensation feature or the battery charge temperature compensation feature can be programmed to use the average or highest value of all battery temperature probes The battery charge temperature compensation feature allows the controller to automatically increase or decrease the output voltage of the system to maintain battery float current as battery temperature decreases or increases respectively B...

Page 129: ...ty 16 26 AWG Recommended Torque 2 2 in lbs MA4C5U31 IB2 DI1 DI1 DI2 DI2 DI3 DI3 J3 J4 J5 J6 J7 J8 J9 DI4 DI4 DI5 DI5 DI6 DI6 DI7 DI7 DI8 DI8 DO1_NC DO2_NC DO1_COM DO2_COM DO1_NO DO2_NO DO3_NC DO4_NC DO3_COM DO4_COM DO3_NO DO4_NO DO5_NC DO6_NC DO5_COM DO6_COM DO5_NO DO6_NO DO7_NC DO8_NC DO7_COM DO8_COM DO7_NO DO8_NO J11 1 J11 2 J11 3 J12 1 J12 2 J12 3 2 4 3 1 J2 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1 ...

Page 130: ...J3 1 2 J3 4 J3 3 3 J3 6 J3 5 4 J4 2 J4 1 5 J4 4 J4 3 6 J4 6 J4 5 7 J5 2 J5 1 8 J5 4 to customer ESTOP switch ESTOP J5 3 48 VDC J5 5 not used not used not used J5 6 NOTE 48V is factory wired to the Digital Input 8 terminal for your convenience and function predefined for ESTOP Customer furnished system ground applied to terminal Digital Input 8 activates the ESTOP function The ESTOP function shuts ...

Page 131: ...7 6 COM J7 4 NC J7 2 5 NO J8 5 COM J8 3 NC J8 1 6 NO J8 6 COM J8 4 NC J8 2 7 NO J9 5 COM J9 3 NC J9 1 8 NO J9 6 COM J9 4 NC J9 2 NOTE The relay assigned to Critical Summary alarm relay 1 on first IB2 by default will operate in the Fail Safe Mode Fail Safe Mode means Relay 1 is de energized during an alarm condition opening the contacts between the C and NO terminals and closing the contacts betwee...

Page 132: ...t input on the EIB Connect the negative side of the shunt to the negative shunt input on the EIB Voltage Inputs for Battery Block and Battery Midpoint Monitoring The controller can monitor battery blocks 12V blocks or midpoint battery voltage of battery strings connected to the EIB Each EIB provides a total of eight 8 DC voltage inputs for these connections An alarm is Issued when either battery b...

Page 133: ...or battery midpoint monitoring per site requirements The controller issues an alarm when any battery midpoint voltage of any battery string has an abnormal value The alarm is Issued when the difference between any battery midpoint voltage and a reference voltage is greater than the value of the block voltage difference setting Block In Use Set to number of 12V battery blocks being used ...

Page 134: ...attery String 2 Battery String 3 EIB Board Voltage Inputs Battery String 4 Battery String 5 Battery String 6 Battery String 7 Battery String 8 Rectifiers Return 48V Load Shunt Load Battery String 1 to DCV1 J6 1 to DCV2 J6 2 to DCV3 J6 3 to DCV4 J6 4 to DCV5 J6 5 to DCV6 J6 6 to DCV7 J7 1 to DCV8 J7 3 Battery String 2 EIB Board Voltage Inputs Rectifiers 12V 12V 12V 12V 12V 12V 12V 12V 12V 12V 12V 1...

Page 135: ...Instructions UM1M820BNA or UM1M820DNA400 or NCU Instructions UM1M830BNA for programming information Relay Ratings Refer to the following a 1A Steady State 30V DC b 3A Peak 30V DC The relays may be preprogrammed for specific functions Refer to the configuration drawing C drawing supplied with your system for your system s specific configuration Temperature Probes Temperature probes can be connected...

Page 136: ...G Recommended Torque 2 2 in lbs EIB Board MA455U41 EIB SH1 SH1 SH2 SH2 SH3 SH3 J5 J6 J7 J8 J9 DCV1 DCV2 DCV3 DCV4 DCV5 DCV6 DCV7 D13_NC DCV8 D13_COM DO9_NC D10_NC DO9_COM D10_COM DO9_NO D10_NO D11_NC D12_NC D11_COM D12_COM D11_NO D12_NO J3 1 J3 2 J3 3 J4 1 J4 2 J4 3 2 4 3 1 J2 D13_NO 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 12 3 4 5 6 1 23 4 5 6 SHUNT INPUTS VOLTAGE INPUTS RELAY OUTPUTS EIB TEMP PROBE ...

Page 137: ...nt Inputs EIB Shunt Input EIB Pin No Factory Wiring Default Function Customer Defined Function Sh1 J5 2 none J5 1 Sh2 J5 4 none J5 3 Sh3 J5 6 none J5 5 Table 10 Voltage Inputs EIB Voltage Input EIB Pin No Default Function 1 J6 1 Battery Block Monitoring 2 J6 2 3 J6 3 4 J6 4 5 J6 5 6 J6 6 7 J7 1 8 J7 3 ...

Page 138: ...o the configuration drawing C drawing supplied with your system for your system s specific relay labeling Optional SM DU and Shunt Interface Board The optional SM DU and Shunt Interface Board provides connections for up to twenty five 25 shunt inputs Inputs are factory connected to any distribution positions devices containing shunts Refer to Figure 64 Procedure Current Inputs Connect up to twenty...

Page 139: ...T23 SHUNT23 SHUNT22 SHUNT22 SHUNT21 SHUNT21 SHUNT20 SHUNT20 SHUNT19 SHUNT19 SHUNT18 SHUNT18 SHUNT17 SHUNT17 SHUNT16 SHUNT16 SHUNT15 SHUNT15 SHUNT14 SHUNT14 TB2 25A 25B 24A 24B 23A 23B 22A 22B 21A 21B 20A 20B 19A 19B 18A 18B 17A 17B 16A 16B 15A 15B 14A 14B SHUNT12 SHUNT12 SHUNT13 SHUNT13 SHUNT11 SHUNT11 SHUNT10 SHUNT10 SHUNT9 SHUNT9 SHUNT8 SHUNT8 SHUNT7 SHUNT7 SHUNT6 SHUNT6 SHUNT5 SHUNT5 SHUNT4 SHU...

Page 140: ... Module Procedure The analog output of the SM Temp Module may be connected to a controller s temperature port input In lieu of connecting the analog output of the SM TEMP module to a temperature port input the SM TEMP module can simply be connected at the end of the Controller s CAN Bus for system s equipped with an ACU requires ACU version 3 02 or later Refer to the SM Temp Module Instructions UM...

Page 141: ...over or straight cable connected directly between your PC and the controller WARNING The intra building port s of the equipment or subassembly is suitable for connection to intra building or unexposed wiring or cabling only The intra building port s of the equipment or subassembly MUST NOT be metallically connected to the interfaces that connect to the OSP or its wiring These interfaces are design...

Page 142: ...roller Ethernet Port NOTE NCU ONLY If your system has an IB4 board DO NOT connect your Local Area Network LAN to the NCU front Ethernet port See NCU Controller Second Ethernet Port Connection if IB4 board furnished on page 144 ESC ENT NCU ACU 10 100M Ethernet Port RJ 45 10 100M Ethernet Port RJ 45 ESC ENT ...

Page 143: ...h the lances on the chassis then goes up to be bundled with the harness and all other customer alarm and signal cables The existing cable ties can also be used to secure the Ethernet cable as it goes up to the top panel Figure 66 Network Connection through Power System Bracket notch Lance Removed some parts for illustrative purposes Cable ties Ethernet wire coming out from one of the rectangular o...

Page 144: ...ructions UM1M830BNA for operational details WARNING The intra building port s of the equipment or subassembly is suitable for connection to intra building or unexposed wiring or cabling only The intra building port s of the equipment or subassembly MUST NOT be metallically connected to the interfaces that connect to the OSP or its wiring These interfaces are designed for use as intra building inte...

Page 145: ...talled in the 1st Supplemental Bay to the top connector SM_CAN IN of the CAN Interface Circuit Card in the 2nd Supplemental Bay Continue connecting RECT CAN OUT to SM_CAN IN on the next supplemental bay until all bays have been connected Insert the CAN terminator into RECT_CAN OUT of the last bay 5 If the multi bay plant is equipped with more than seventy two 72 rectifier slots for 1R483500E3 or 1...

Page 146: ...nstallation Manual IM582127000 Rev BB 146 Figure 68 Bay to Bay Communications Cable Connections cont d on next page Main Bay 1st Supplemental Bay 2nd to 6th Supplemental Bays Front doors remove in illustration for clarity only Continued on next page ...

Page 147: ...N IN OUT RECT_CAN MAIN BAY CAN2 CAN1 RECT_CAN OUT SM_CAN 1 BAY SYSTEM 2 BAY SYSTEM 3 BAY SYSTEM 4 BAY SYSTEM IN OUT IN OUT IN RECT_CAN OUT SM_CAN IN OUT IN CAN2 SUPP BAY 1 SUPP BAY 1 SUPP BAY 2 SUPP BAY 1 SUPP BAY 2 SUPP BAY 1 SUPP BAY 2 SUPP BAY 3 SUPP BAY 3 SUPP BAY 4 1 Diagrams above are for typical configurations CAN1 is used for all SM_CAN connections and for RECT_CAN connections up through a...

Page 148: ... 3 8 Belleville Lockwasher concave side of Belleville Lock Washers face each other 3 8 Belleville Lockwasher 3 8 Flat Washer Torque to 180 in lbs Return Interbay Busbar Secure in 4 places with in order listed 3 8 16 x 1 1 4 Bolt 3 8 Belleville Lockwasher concave side of Belleville Lock Washers face each other 3 8 Belleville Lockwasher 3 8 Flat Washer Torque to 180 in lbs 1 4 20 Insulator Standoff ...

Page 149: ...3 Only for system mounted in a relay rack cont d from previous page ATTACH REAR COVER SHIELDS ASSEMBLED VIEW 7 Secure rear cover shields to previously installed insulator standoffs using 1 4 20 x 1 2 Bolt and 1 4 Flat Washer 2 places each shield 8 Secure rear cover shields to distribution cabinets using 6 32 x 3 8 screws 2 places each shield ...

Page 150: ...ted 3 8 16 x 1 3 4 Bolt 3 8 Belleville Lockwasher concave side of Belleville Lock Washers face each other 3 8 Belleville Lockwasher 3 8 Flat Washer Torque to 180 in lbs 3 8 16 x 1 3 4 Bolt 3 8 Belleville Lockwasher concave side of Belleville Lock Washers face each other 3 8 Belleville Lockwasher 3 8 Flat Washer Torque to 180 in lbs 48V Angle Brackets Secure in 2 places with in order listed 3 8 16 ...

Page 151: ...bs 48V Interbay Busbar Secure in 4 places with in order listed 5 16 18 x 1 3 4 Bolt 5 16 Belleville Lock Washer 5 16 Hardened Flat Washer 4 places Torque to 108 in lbs Components removed in illustration for clarity only Close Up View Showing Spacer Orientation Assembling Return Interbay and 48V Interbay Busbars Return Interbay and 48V Interbay Busbars Assembled View Return Label 48V Label 5 16 18 ...

Page 152: ...8 Only for system mounted in an enclosure cont d from previous page ASSEMBLED VIEW 8 Attach L Shaped Brackets to cabinet side wall 9 Tighten bracket to insulator bolt 10 Re Install cabinet rear panels 8 32 x 3 8 Bolt Torque to 20 in lbs 8 32 x 3 8 Bolt Torque to 20 in lbs 1 4 20 x 1 2 Bolt 1 4 Lock Washer 1 4 Flat Washer Torque to 84 in lbs ...

Page 153: ...nectors are used to interconnect the shelves to the controller Refer to Figure 71 for connector locations These connections are factory made for shelves factory installed The connection must be made if a rectifier field expansion shelf is installed as shown in Figure 71 For field expansion refer to the procedure in Power System User Instructions UM582127000 The top connector of the top most module...

Page 154: ...dule Mounting Shelf These cables are factory connected These cables are factory connected These cables are factory connected Existing Rectifier Module Mounting Shelf Expansion Rectifier Module Mounting Shelf Exploded View Shown to Illustrate Wire Connections Only Disconnect cable coming from distribution cabinet from this connector on bottom most existing rectifier shelf then connect to the top co...

Page 155: ...ar of each shelf These connectors are used to interconnect the shelves to the controller and to other shelves The right side connector is factory jumpered so both connectors can be accessed from the left side of the shelf Refer to Figure 72 for connector locations and an interconnect diagram These connections are factory made for shelves factory installed The connection must be made if a rectifier...

Page 156: ...se connectors are factory connected These connectors are factory connected Existing Module Mounting Shelf Expansion Module Mounting Shelf Disconnect cable coming from distribution cabinet from this connector on bottom most existing shelf then connect to the same connector on the expansion shelf Now connect these two connectors together Rear View Factory provided jumper to bring connectors to same ...

Page 157: ... each shelf These connectors are used to interconnect the shelves to the controller and to other shelves In expansion shelves these connectors are factory jumpered so both connectors can be accessed from the center of the shelf Refer to Figure 73 for connector locations and an interconnect diagram These connections are factory made for shelves factory installed The connection must be made if a rec...

Page 158: ...ttom most existing shelf Adding Second Expansion Shelf Disconnect cable 562086 from cable BMY200005 1 in center section of first expansion shelf then connect cable 562086 to cable BMY200005 1 in center section of second expansion shelf Then connect cable BMY200004 1 in center section of second expansion shelf to cable BMY200005 1 in center section of first expansion shelf Distribution Cabinet Wire...

Page 159: ...s before connecting Mount two lugs back to back per mounting position if required Torque as shown in Figure 74 5 Continue with the next procedure Connecting List 60 Converter Output Cables to Module Mounting Assembly s Spec No 588705300 Procedure 1 Route the output cables installed in the previous procedure over the top of the distribution bus panel ground bar toward the back of the cabinet and do...

Page 160: ...lt Torque to 84 in lbs To List DA DB DC DD DE DF DG DH and DJ Dual Voltage Distribution Panel This end is connected to rectifier converter shelf 24V bus see next illustration Hardware provided with Converter Option Kit P N 556228 Converter Output Cable List DG Lists DE DF DH DJ and DK similar Rear Front Connect jumpers to an available landing here Assembly order is lug 1 4 flat washer 1 4 lock was...

Page 161: ...us page cont d on next page TORQUE CONNECTIONS TO 84 IN LBS To List DA DB DC DD DE DF DG DH and DJ Dual Voltage Distribution Panel see previous illustration P N 556228 Converter Output Cable Assembly order is 1 4 20 x 1 bolt 1 4 lock washer 1 4 flat washer lug 24V Busbar 1 4 flat washer 1 4 20 nut 24V Bus Lugs may be mounted on both sides of this busbar ...

Page 162: ...nections Loads are connected to the various distribution panels located inside the distribution cabinet s as detailed in this section Recommended Torques 72 in lbs for 1 4 inch hardware when using standard flat and lock washer 300 in lbs for 3 8 inch hardware when using standard flat and lock washer ...

Page 163: ...rder additional hardware Maximum Lug Width 0 625 inches Return Busbar not included with List AB Observe proper polarity when making load connections WARNING Caution 100 A circuit breakers and fuses can be used without a space provided the continuous operating current in each 100 A device does not exceed 64 A A 175 A or greater circuit breaker shall have an empty mounting position between it and an...

Page 164: ... Shunts without Return Busbar 48VDC Load Connections LOAD CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Customer must supply or order additional hardware Maximum Lug Width 1 88 inches Observe proper polarity when making load connections WARNING 48VDC Load Connections LOAD CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Customer must supply or order additional hardware Maximum Lug Width 1 88 inches Obs...

Page 165: ...bar 48VDC Load Connections LOAD CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Customer must supply or order additional hardware Maximum Lug Width 1 75 inches Maximum fuse size is 400A Observe proper polarity when making load connections WARNING 48VDC Load Connections LOAD CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Customer must supply or order additional hardware Maximum Lug Width 1 75 inches Max...

Page 166: ...tions with Shunts without Return Busbar 48VDC Load Connections LOAD CONNECTIONS 3 8 16 Studs on 1 Centers Customer must supply or order additional hardware Maximum Lug Width 1 5 inches Observe proper polarity when making load connections WARNING 48VDC Load Connections LOAD CONNECTIONS 3 8 16 Studs on 1 Centers Customer must supply or order additional hardware Maximum Lug Width 1 5 inches Observe p...

Page 167: ... or order additional hardware Maximum Lug Width 0 625 inches Return Busbar not included with List AN Caution A 100 A circuit breakers and fuses can be used without a space provided the continuous operating current in each 100 A device does not exceed 64 A A 175 A or greater circuit breaker shall have an empty mounting position between it and any other overcurrent protective device Observe proper p...

Page 168: ...tion 24V Distribution Observe proper polarity when making load connections WARNING Caution A 100 A circuit breakers and fuses can be used without a space provided the continuous operating current in each 100 A device does not exceed 64 A A 175 A or greater circuit breaker shall have an empty mounting position between it and any other overcurrent protective device Load Connections Load Return Conne...

Page 169: ...rve proper polarity when making load connections WARNING Caution 100 A circuit breakers and fuses can be used without a space provided the continuous operating current in each 100 A device does not exceed 64 A A 175 A or greater circuit breaker shall have an empty mounting position between it and any other overcurrent protective device Load Connections 48V Distribution 24V Distribution Load Return...

Page 170: ...imum Lug Width 0 625 inches Load Connections Load Return Connections Caution 100 A circuit breakers and fuses can be used without a space provided the continuous operating current in each 100 A device does not exceed 64 A A 175 A or greater circuit breaker shall have an empty mounting position between it and any other overcurrent protective device Observe proper polarity when making load connectio...

Page 171: ...ximum Lug Width 0 625 inches Load Connections Load Return Connections Caution 100 A circuit breakers and fuses can be used without a space provided the continuous operating current in each 100 A device does not exceed 64 A A 175 A or greater circuit breaker shall have an empty mounting position between it and any other overcurrent protective device Observe proper polarity when making load connecti...

Page 172: ...ad Connections Load Return Connections Caution 100 A circuit breakers and fuses can be used without a space provided the continuous operating current in each 100 A device does not exceed 64 A A 175 A or greater circuit breaker shall have an empty mounting position between it and any other overcurrent protective device 24V Distribution LOAD AND LOAD RETURN CONNECTIONS 1 4 20 Studs on 5 8 Centers Cu...

Page 173: ...attery Return Connections LOAD AND OR BATTERY RETURN CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Customer must supply or order additional hardware Maximum Lug Width 1 38 inches Observe proper polarity when making load connections WARNING Load Return Connections LOAD AND LOAD RETURN CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Customer must supply or order additional hardware Maximum Lug Width 2 0...

Page 174: ...se Block Wire Size Capacity 26 14 AWG Recommended Torque 4 5 in lbs 35A maximum capacity per block Maximum GMT fuse size is 15A Wire Size Capacity 26 14 AWG Recommended Torque 4 5 in lbs 35A maximum capacity per block Maximum GMT fuse size is 15A Load Return Leads 48VDC Load Leads 1 4 20 Hardware Torque to 75 in lbs Part of P N 549017 Part of P N 549017 Load Return Leads 48VDC Load Leads P N 55022...

Page 175: ...hardware when using standard flat and lock washer 300 in lbs for 3 8 inch hardware when using standard flat and lock washer 180 in lbs for 3 8 inch hardware when using a Belleville lock washer Battery Connections to Optional Battery Disconnect Distribution Panels DANGER Adhere to the Important Safety Instructions presented at the front of this document Battery strings are connected to the various ...

Page 176: ...Maximum Lug Width 0 625 inches Customer must supply or order additional hardware Return Busbar not included with List BB Observe proper polarity when making battery connections WARNING Caution 100 A circuit breakers and fuses can be used without a space provided the continuous operating current in each 100 A device does not exceed 64 A A 175 A or greater circuit breaker shall have an empty mountin...

Page 177: ...Disconnect Positions with Shunts without Return Busbar 48VDC Battery Connections BATTERY CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Maximum Lug Width 1 88 inches Customer must supply or order additional hardware Observe proper polarity when making battery connections WARNING 48VDC Battery Connections BATTERY CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Maximum Lug Width 1 88 inches Customer must...

Page 178: ... Shunts without Return Busbar 48VDC Battery Connections BATTERY CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Customer must supply or order additional hardware Observe proper polarity when making battery connections WARNING Maximum Lug Width 1 75 inches Maximum fuse size is 400A 48VDC Battery Connections BATTERY CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Customer must supply or order additional h...

Page 179: ...ay rack 4 Row Cabinet Shown Others Similar Battery Return Side Busbar Battery Return Side Busbar Battery Load Side Busbar Battery Load Side Busbar GND RTN 48V SUPPLY BATTERY AND BATTERY RETURN CONNECTIONS 7 landings per polarity 3 8 16 Captive Nuts on 1 Centers Customer must supply additional hardware Maximum Lug Width 1 88 inches unless otherwise noted Maximum Lug Width 1 25 inches this location ...

Page 180: ...tery Return Side Busbar Battery Load Side Busbar BATTERY AND BATTERY RETURN CONNECTIONS 7 landings per polarity 3 8 16 Captive Nuts on 1 Centers Customer must supply additional hardware Maximum Lug Width 1 25 inches this location only 3 Row and 4 Row Cabinets Central Office Ground Power System Installed in a Cabinet Front View Battery Return Side Busbar Battery Load Side Busbar GND RTN 48V SUPPLY ...

Page 181: ...00 0 000 0 000 0 000 0 750 0 750 0 750 1 750 1 750 3 750 2 250 4 000 0 000 0 750 1 750 0 000 0 750 1 750 0 000 0 750 1 750 0 000 0 750 1 750 4 000 4 000 3 8 16 Captive Nut 3 8 16 Captive Nut 3 8 16 Captive Nut 3 8 16 Captive Nut 3 8 16 Captive Nut 3 8 16 Captive Nut 3 8 16 Captive Nut 3 8 16 Captive Nut 3 8 16 Captive Nut 1 000 2 880 4 760 6 640 0 000 0 000 5 000 7 000 9 000 4 250 0 000 0 740 1 00...

Page 182: ...bars located on the rear of the distribution cabinets as detailed in Figure 107 depending on site requirements Figure 107 Battery Connections to Bay to Bay Rectifier Busbars for system mounted in a relay rack RECTIFIER AND RECTIFIER RETURN CONNECTIONS CAN ONLY BE USED FOR BATTERY CONNECTIONS IF THE SYSTEM DOES NOT CONTAIN A BATTERY SHUNT OR BATTERY DISCONNECT CONTACTOR 3 8 16 Captive Nuts on 1 Cen...

Page 183: ...his document Figure 108 Battery Connections to Optional Battery Busbar Extension Kit P N 562364 for system mounted in a relay rack Battery Return Side Busbar Battery Load Side Busbar GND RTN 48V SUPPLY BATTERY BUSBAR EXTENSION KIT P N 562364 3 8 Clearance Holes on 1 Centers Customer must supply additional hardware Note Central Office Ground should be tied to any point on the battery return busbar ...

Page 184: ...ystem mounted in an enclosure BATTERY BUSBAR EXTENSION KIT P N 562364 3 8 Clearance Holes on 1 Centers Customer must supply additional hardware Note Central Office Ground should be tied to any point on the battery return busbar or battery return extension busbar Power System Installed in a Cabinet Front View Battery Return Side Busbar Battery Load Side Busbar GND RTN 48V SUPPLY ...

Page 185: ...afety Instructions presented at the front of this document Figure 110 Battery Connections to Optional Battery Busbar Extension Kit P N 562364 for system mounted in an enclosure Front View One Row Cabinet Shown Others Similar Battery Return Side Busbar Battery Load Side Busbar GND RTN 48V SUPPLY BATTERY BUSBAR EXTENSION KIT P N 554541 3 8 Clearance Holes on 1 Centers Customer must supply additional...

Page 186: ...ty Instructions presented at the front of this document Figure 111 Battery Connections to Optional Battery Landing Busbar Kit P N 553584 for system mounted in a relay rack Rear View GND RTN 48V SUPPLY Plastic Shield Up to Six 6 Battery Leads per polarity 1 4 20 x 0 875 Studs on 0 625 Centers 24 Places Customer must supply additional hardware One Row Cabinet Shown Others Similar Battery Return Side...

Page 187: ...is document Figure 112 Battery Connections to Optional Battery Landing Busbar Kit P N 555478 for system mounted in a relay rack 1 4 20 x 0 875 Studs on 0 625 Centers 16 Places Customer must supply additional hardware Two Row Cabinet Shown Others Similar Rear View GND RTN 48V SUPPLY Plastic Shield Up to Eight 8 Battery Leads per polarity Four 4 battery landing positions two 2 battery cable lugs bac...

Page 188: ...to System Application Guide SAG582127000 for specifications and manufacturers of the batteries to be installed in this power system Installing Battery Landing Busbar Kit P N 553584 List 21 or 555478 List 22 23 or 24 DANGER Adhere to the Important Safety Instructions presented at the front of this document If the battery tray s was ordered with the system these kits were installed at the factory If...

Page 189: ...et Secure 2 places with in order listed 3 8 16 x 1 1 4 Bolt 3 8 Belleville Lockwasher and 3 8 Flat Washer Torque to 180 in lbs 48V Angle Bracket Secure 2 places with in order listed 3 8 16 x 1 1 4 Bolt 3 8 Belleville Lockwasher and 3 8 Flat Washer Torque to 180 in lbs Apply electrical anti oxidizing compound to busbar mating surfaces Rear cover removed in illustration for clarity only Hardware att...

Page 190: ...et 4 Secure rear cover shield to distribution cabinet after wiring Return Angle Bracket Secure 2 places with in order listed 3 8 16 x 1 1 4 Bolt 3 8 Belleville Lockwasher and 3 8 Flat Washer Torque to 180 in lbs 48V Angle Bracket Secure in 2 places with existing hardware in order listed 1 2 13 x 1 1 4 Bolt 1 2 Belleville Lockwasher 1 2 Flat Washer Torque to 200 in lbs Two Row Cabinet Shown Others ...

Page 191: ...ented at the front of this document If the battery tray s was ordered with the system wiring to the battery tray was performed at the factory If a battery tray is installed in the field customer must wire to the battery tray Procedure 1 Refer to the wiring diagram provided in Figure 115 and wire the battery tray for your application Refer also to Figure 113 or Figure 114 ...

Page 192: ... Power System Installation Manual IM582127000 Rev BB 192 Figure 115 Wiring Diagram List 93 Battery Tray cont d on next page 559814 559816 559806 559814 559816 559806 559814 559816 559806 559814 559816 559813 559814 559815 559816 559806 ...

Page 193: ... Installation Manual IM582127000 Rev BB 193 Figure 115 Wiring Diagram List 93 Battery Tray cont d from previous page cont d on next page 559813 559814 559815 559816 559806 559806 559806 559806 559813 559815 559813 559815 559813 559815 559813 559815 ...

Page 194: ...Vertiv NetSure 7100 Series 48V DC Power System Installation Manual IM582127000 Rev BB 194 Figure 115 Wiring Diagram List 93 Battery Tray cont d from previous page 559806 559806 559806 559806 ...

Page 195: ...l the battery retention bracket The spacers on the bracket should separate the batteries from each other Secure with the hardware removed in a previous step Refer to Figure 116 for washer location 5 Connect three links supplied by the battery manufacturer between pairs of battery terminals as shown in Figure 116 Use hardware furnished by the battery manufacturer Torque hardware to battery manufact...

Page 196: ... Washer 1 4 Flat Washer 3 places Connect Link Furnished with Battery to these Two Terminals If trays are equipped with circuit breakers TURN OFF ALL circuit breakers before installing and connecting any batteries Connect NEG Battery Cable to this Terminal Connect Link Furnished with Battery to these Two Terminals Connect Link Furnished with Battery to these Two Terminals DETAIL A Alternate Orienta...

Page 197: ...removing a module NEVER hold the handle in the closed position when installing a module into a shelf NOTE 588705000 List 32 and List 33 Rectifier Mounting Assemblies Only 3 Phase Input One three phase input feeds the three rectifier modules on the left hand side of the shelf The second three phase input feeds the modules on the right hand side To maintain phase balance install rectifier modules in...

Page 198: ...Vertiv NetSure 7100 Series 48V DC Power System Installation Manual IM582127000 Rev BB 198 Figure 117 Installing Rectifier or Converter Modules into Spec No 588705000 Module Mounting Assembly ...

Page 199: ...g Assemblies Only 3 Phase Input One three phase input feeds the three rectifier modules on the left hand side of the shelf The second three phase input feeds the modules on the right hand side To maintain phase balance install rectifier modules in groups of three that is fill all three mounting positions on the left and or all three on the right Procedure 1 Unpack the rectifier modules 2 If presen...

Page 200: ...Vertiv NetSure 7100 Series 48V DC Power System Installation Manual IM582127000 Rev BB 200 Figure 118 Installing Rectifier Modules into Spec No 588705500 Module Mounting Assembly ...

Page 201: ...ing or removing a module NEVER hold the handle in the closed position when installing a module into a shelf Procedure 1 Unpack the modules 2 Note the model number located on the front of each module Model numbers starting with the letter R are rectifier modules Model numbers starting with the letter C are converter modules 3 Place the module into an unoccupied mounting position without sliding it ...

Page 202: ...ling Rectifier and Converter Modules into Spec No 588705300 Module Mounting Assembly Module Mounting Shelf s Rectifier Mounting Positions Rectifier or Converter Mounting Positions Front View Rectifier or Converter Module Model Number Label R48 2000e3 Rectifier C48 24 1500 Converter Captive Screw Latch Handle ...

Page 203: ... phase input feeds the three rectifier modules on the left hand side of the shelf The second three phase input feeds the modules on the right hand side To maintain phase balance install rectifier modules in groups of three that is fill all three mounting positions on the left and or all three on the right Procedure 1 Unpack the rectifiers 2 If present remove blank cover panels from the module moun...

Page 204: ...Vertiv NetSure 7100 Series 48V DC Power System Installation Manual IM582127000 Rev BB 204 Figure 120 Installing Rectifiers into Spec No 588705400 Module Mounting Assembly ...

Page 205: ...rs Initially Starting the System Procedure 1 Apply battery power to the system by closing the external battery disconnect s or protective device s that supplies battery power to the system if furnished Close the system s internal battery disconnect circuit breakers if furnished 2 Apply AC or DC input power to the system depending on configuration ordered by closing ALL external AC or DC disconnect...

Page 206: ...Plus Version Starting 2 Next the language screen appears Press the up or down arrow key to select the desired language Press the ENT key to confirm the selection If no key is pressed within 10 seconds the ACU selects the displayed language automatically 3 As initialization continues the Main screen is displayed but with zero volts Initialization is not complete 4 When initialization is complete th...

Page 207: ...four remaining rectifiers until the controller can send updated set points to the remaining rectifiers This takes a couple communication cycles several seconds after which each rectifier would have a new set point of 37 5 amps for a total of 150 amps The total current limit of the rectifiers and converters should not be set such that the loss of the redundant rectifiers or converters will cause th...

Page 208: ...elect User field Press ENT Use the UP and DOWN keys to select a User previously programmed into the ACU Press ENT to select the User Note that only Users programmed into the ACU are shown Users are programmed via the Web Interface The default User is admin 3 To Enter a Password If a password screen opens a password must be entered to allow the User to make adjustments To enter a password use the U...

Page 209: ...Basic BTRM Action Main Menu Settings Battery Basic BTRM Voltage Temperature Compensation Center Temperature Main Menu Settings Battery Temp Comp Temp CompCenter Temperature Compensation Slope Main Menu Settings Battery Temp Comp Temp Comp Coeff Temperature Compensation Sensor Main Menu Settings Battery Temp Comp TempComp Sensor Temperature Compensation Maximum Voltage Main Menu Settings Battery Te...

Page 210: ... next lowest is Rect 2 etc If you prefer the ACU to identify the rectifiers by position in the system perform the following procedure Upon power up the ACU arbitrarily assigns Phase A B or C to each rectifier This assignment is used to display rectifier AC input phase voltage s The User may reassign the phase to each rectifier per your specific installation by following the procedure below Procedu...

Page 211: ...the converters is by serial number lowest serial number is Conv 1 next lowest is Conv 2 etc If you prefer the ACU to identify the converters by position in the system perform the following procedure Procedure 1 With the Main screen displayed press ENT to go to the Main Menu Navigate to and select Settings ENT 2 If a password screen opens a password must be entered to allow the User to make adjustm...

Page 212: ...ENT to select the operation Press ENT again to confirm NOTE Check you numbering to be sure it is correct If there where conflicts in your numbering converters with conflicts will be assigned the next available sequential number 13 Return to the Main screen by repeatedly pressing ESC escape ACU Alarm Relay Check To verify operation of the external alarm relays use the ACU alarm relay test feature R...

Page 213: ...hat time various alarm indicators may illuminate on the NCU front panel and an audible alarm may sound Disregard all alarms An audible alarm can be silenced at any time by momentarily depressing the ENT key on the NCU Controller 1 After the NCU is powered on the display shows the logo screen The controller is initializing 2 When initialization is complete the language screen appears Press the up o...

Page 214: ...ight the desired Menu graphic in the Main Menu Press the ENT key to enter the selected menu NOTE Repeatedly press the ESC key to return in reverse order level by level from any submenu until the Main Menu appears 6 Verify and set the NCU controller as required for your application Refer to the NCU Instructions UM1M830BNA for procedures Note that you will have to program the NCU for any temperature...

Page 215: ... to enter basic programmable parameters in one session Refer to the Start Wizard section in the NCU Instructions UM1M830BNA Verifying the Configuration File Your NCU was programmed with a configuration file that sets all adjustable parameters The version number of the configuration file can be found on the configuration drawing C drawing that is supplied with your power system documentation and on...

Page 216: ...ld Press ENT Use the UP and DOWN keys to choose a character Press ENT to accept and move to the next character Continue this process until all characters are entered Press ENT again to accept the password The default password is 640275 4 To Change a Parameter Press the UP and DOWN keys to move up and down the list of parameters Press ENT to select the parameter Press the UP and DOWN keys to change...

Page 217: ...Parameters IP address subnet mask address gateway address Main Menu Settings Icon Comm Settings enter parameters Float Voltage Main Menu Settings Icon Batt Settings Charge Float Voltage Equalize Voltage Main Menu Settings Icon Batt Settings Charge EQ Voltage Battery Capacity Main Menu Settings Icon Batt Settings Batt1 Settings or Batt2 Settings Rated Capacity Battery Charge Temperature Compensatio...

Page 218: ...rform the following procedure Upon power up the NCU arbitrarily assigns Feed AC1 AC2 or AC3 to each rectifier This assignment is used to display rectifier AC input feed voltage s The User may reassign the feed to each rectifier per your specific installation by following the procedure below Local Menu Navigation None Web Menu Navigation Refer to the NCU Instructions UM1M830BNA for detailed instruc...

Page 219: ...system is operating normally the status of these is as shown in Table 16 Table 16 Status and Alarm Indicators Component Indicator Normal State ACU Status Green On Minor Yellow Off Critical or Major Alarm Red Off NCU Status Green On Minor Yellow Off Critical or Major Alarm Red Off Rectifier Modules or Power Green On or Protection Yellow Off or Alarm Red Off Converter Modules or Power Green On or Pr...

Page 220: ... a later date NOTE Note that provided on a USB drive furnished with the system is a controller configuration drawing C drawing and the controller configuration files loaded into the controller as shipped 2 Close the distribution cabinet s front door and turn the latch clockwise to secure the door system s in a relay rack or close the system s enclosure door 3 Verify all rectifier and converter mod...

Page 221: ...Vertiv NetSure 7100 Series 48V DC Power System Installation Manual IM582127000 Rev BB 221 This page is intentionally blank ...

Page 222: ...VertivCo com Vertiv Headquarters 1050 Dearborn Drive Columbus OH 43085 USA IM582127000 RBB 02 19 ...

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